Microstructure and Mechanical Properties of Aluminum Alloy Studs Using Wire–Laser Directed Energy Deposition

In this study, an annular laser beam shaping optics and a wire feeding system are used for additive manufacturing. A discrete concentric layering trajectory strategy (DCL-TS) and a continuous deposition trajectory strategy (CD-TS) for the laser-directed energy deposition (WL-DED) of aluminum alloy stud structures are developed. Initially, combinations of parameters, such as laser power, transverse speed, and wire feeding speed, which lead to a process that produces a single-layer structure with good morphology and no visible pores and cracks, are identified. Then, DCL-TS and CD-TS manufacturing strategies are used to produce aluminum alloy studs of similar dimensions. The EBSD results indicate that the CD-TS produces finer grains in the aluminum alloy studs compared to the DCL-TS; correspondingly, mechanical testing reveals superior microhardness and tensile strength in the circularly fabricated studs. The latter tensile value testing verifies that aluminum alloy studs using WL-DED on the substrate can meet the requirements for practical application in mobile phones, computers, etc. This research method enhances the mechanical properties of additively manufactured items. Consequently, manufacturing efficiency is significantly improved, providing a promising solution for rapid production.